METHOD OF FORMING A STACKED ARTICLE GROUP WITHIN A CARRIER

Abstract: A method of forming stacked article groups wholly or partly within a packaging unit, comprising the steps of supplying a stream of packaging units, supplying at least two streams of articles; forming a stream of first article groups having at least one article; placing a support base on a top surface of each first article group; and forming a second article group, having at least one article, on top of the support base of each first article group, whereby stacked article groups are formed within the packaging units. Apparatus for implementing the method is also disclosed.

Description: METHOD OF FORMING A STACKED ARTICLE GROUP WITHIN A CARRIER BACKGROUND OF THE INVENTION 1. Field of the Invention. This invention relates to packaging methods and apparatus. Particularly, this invention relates to a method of forming stacked or multiple layer article groups inside packaging media, which utilizes a divider panel between top and bottom members of each group. The packaging method of the present invention is usable to package different types, styles and sizes of articles, in a wide range of stacked group patterns, and into a variety of packaging media, in a fast and reliable manner. 2. Background of the Invention. In the past, various apparatus and processes have been proposed and utilized to package selected article groups. Prior art apparatus and processes have limited adjustability, limited output capability, and have been difficult to construct and utilize. And, no process or apparatus, insofar as is known, provides reliable, high speed packaging of stacked or layered product groups. Prior art packaging assemblies include U.S. Patent 4,802,324 to applicants' assignee for a Vertical Cartoning Assembly and Method which discloses the placement and assembly of cartons over preselected article groups being moved on a conveyor. U.S. Patent 5,036,644, also to applicants' assignee, discloses a Packaging Sleever Assembly which transfers flat packaging sleeves directly onto preselected article groups and subsequently wraps and closes the cartons. Various end loading packaging machines have also been proposed in the art. For example, U.S. Patent 3,778,959 to Langen et al. discloses an end loader which utilizes a plurality of transversely extending spaced apart fences or flights mounted on a conveyor to rake or capture a predetermined number of containers from infeed container slips. U.S. Patent 4,237,673 to Calvert et al. discloses a machine also for loading container sleeves through their open ends. U.S. Patent 4,936,077 to Langen et al. discloses a carton loading machine which utilizes pusher mechanisms with spring loaded pusher heads to stagger adjacent product group rows during transfer into the carton. In view of the limitations and shortcomings of prior art processes and apparatus, it is an object of this invention to provide a method of reliably forming stacked product groups at high speed. Another object of this invention is to provide a packaging method which is usable with a variety of package types, articles and stacked group configurations and sizes. A particular object of the invention is to provide a method of forming stacked or multiple layer article groups either wholly or partly within a packaging member, via a base member disposed between a lower article sub-group and an upper article sub-group. SUMMARY OF THE INVENTION The present invention provides a method forming stacked article groups within a packaging unit, comprising the steps of: supplying a stream of packaging units, for example paperboard cartons, supplying at least two streams of articles, for example beverage cans; forming first article groups having at least one article, for example a group of six or twelve cans, in the packaging unit; placing a support base on a top surface of each first article group; forming a second article group, having at least one article, on top of the support base on each first article group, whereby stacked article groups are formed in the packaging unit. Various embodiments of the basic method are disclosed, including continuous and intermittent methods, methods of group formation in a linear stream with article input from one or two sides, in staggered orientations, and bi-level and single level input methods. The important aspect of each of the various embodiments of the basic method is that the stacked article group is formed wholly or partly within the packaging unit, and a divider or base support sheet is utilized. In a preferred embodiment, the support base is preferably constructed of paperboard and has a thin, substantially flat, rectilinear configuration with a surface area substantially coextensive with that of the top surface of the first article group. The method is ideally suited for beverage can packaging purposes. The benefits of this invention will become clear from the following description by reference to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a top plan view of one embodiment of the packaging or cartoning method and assembly of the present invention; FIG. 2 is a side view of the assembly shown in FIG. 1; FIG. 3 is a top plan view of another embodiment of the packaging method and assembly; FIG. 4 is a side view of the assembly shown in FIG. 3; FIG. 5 is a top plan view of another embodiment of the packaging method and assembly; FIG. 6 is a side view of the assembly shown in FIG. 5; FIG. 7 is a top plan view of another embodiment of the packaging method and assembly; FIG. 8 is a side view of the assembly shown in FIG. 7; FIG. 9 is a top plan view of another embodiment of the packaging method and assembly; FIG. 10 is a side view of the assembly shown in FIG. 9; FIG. 11 is a crossectional view of the assembly taken along line 11-11 of FIG. 9; FIG. 12 is a crossectional view of the assembly taken along line 12-12 of FIG. 9; FIG. 13 is a perspective view of an exemplary filled carton assembled by the method and assembly of this invention; and FIG. 14 is a crossectional view of the carton taken along line 14-14 of FIG. 13. DESCRIPTION OF THE PREFERRED EMBODIMENT The methods and apparatus of the present invention are for packaging stacked article groups in a high speed operation. As shown in the drawings, the method of this invention is implemented via a high-speed packaging apparatus. The apparatus is adjustable to provide reliable, continuous and high speed packaging of articles or products of varying types, sizes and quantities into packages of varying types and sizes. For example, the apparatus is usable to load standard twelve ounce beverage cans into 24(12/12), 30(15/15) and 36(18/18) pack stacked combinations. Moreover, the process of loading beverage containers into paperboard cartons, for example, is accomplished quickly and reliably, under typical industry tolerances for both container and carton construction. Although the embodiments disclosed load stacked beverage can groups into paperboard cartons, its within the purview of this invention to process stacked groups of articles of a variety of types and sizes and containing a variety of products, into a variety of packaging media. Referring to FIGS. 1 and 2, the one embodiment of the cartoner assembly 10 generally comprises a transport and selection mechanism or stream 11, a pair of article supply mechanisms or streams 12 and 13, a divider placement mechanism 14, and a carton placer 15.. These mechanisms are preferably supported by a unitary frame structure (not shown), although if aligned properly, separate support structures may be utilized consistent with the teachings of this invention. The carton supply mechamsm 15 is shown to be disposed proximate an input end of the assembly 10. Carton sleeves or blanks 16 are shown to be placed by the rotary-type placer 15 between the flight bars 22 of the transport and selection mechanism 11. The cartons 16 are shown to be arranged so that their ends are disposed laterally with respect to the axis of the selection and transport mechanism 11, with their end flaps open. The carton sleeves 16 are subsequently transported in a linear fashion to an output end of the apparatus 10. The article supply mechanisms 12 and 13 are also disposed at the input end of the apparatus 10. A first portion of each article supply mechanism 12 and 13 is disposed spatially parallel to the selection and transport mechanism 11, and a second portion merges, at a predetermined angle, with the selection transport mechanism 11 to supply streams of product or articles 17 to two separate positions along the selection and transport mechamsm 11. Alternatively, the article supply mechamsms 12 and 13 may run straight into the selection and transport mechanism 11 at an angle. Each article supply mechanism 12 and 13 is shown to be separated into a plurality of rectilinear article lanes 23 each with a slotted end. These merging mechamsms 11-13 are further constructed and arranged to meter individual articles 17 by raking the articles from the supply mechamsms 12 sand 13 via a fixed flight bar arrangement 22 which extends through the slotted ends of the article lanes 23, into predetermined stacked article sub-groups 18 and 19 in the cartons 16 traveling on the mechanism 11. The stacking function of the device 10 is accomplished by forming a first group 18 in the carton 16, at a low level, placing a separator or divider sheet 20 on the inserted lower group 18 via the divider sheet placement mechamsm 14 (preferably a lateral sheet feeder), and then forming a second group 19 in the carton 16, downstream at a higher level and allowing the forming upper group 19 to slide across the divider sheet 20 by the action of the flight bars 22 of the selecting mechamsm 11. Merged or combined article groups 21 contained within the cartons 16 are transported downstream in the selection and transport mechanism 11 in a spaced and metered fashion between the flight bars 22. Importantly, each group 21 is disposed in a carton 16 traveling on the selection and transport mechanism 11. Preferably, each of the aforementioned mechamsms 11-15 has a conveyor type structure with an endless chain or belt configured about rotatable drive and idler end means and moving longitudinally with respect to the input (upstream) and output (downstream) ends of the apparatus 10. The movement of each mechamsm is further synchronized with one another, for example by a common drive and/or gearing means. FIGS. 3 and 4 show a second, alternative, embodiment of the method and assembly for packaging a stacked article group in a carton. Basically, the assembly 29 inputs articles from opposite side of the selection and transport stream or line in a staggered orientation. In contrast, the previous embodiment showed article infeed from the same side of the selection and transport line, also in a staggered orientation. The assembly 29 generally comprises a transport and selection mechamsm or stream 30, a pair of article supply mechamsms or streams 31 and 32, a divider placement mechanism 33, and a carton placer 34. These mechamsms are also preferably supported by a unitary frame structure (not shown) Each of the aforementioned mechanisms 29-34 also has a synchronized conveyor type structure with an endless chain or belt configured about rotatable drive and idler end means and moving longitudinally with respect to the input (upstream) and output (downstream) ends of the apparatus 29. The carton supply mechamsm 34 is shown to be disposed proximate an input end of the assembly 29. Carton sleeves or blanks 35 are placed by the rotary-type placer 34 between the flight bars 41 of the transport and selection mechanism 30. The cartons 35 are arranged so that their ends are disposed laterally with respect to the axis of the selection and transport mechamsm 30, with their end flaps open. The carton sleeves 35 are subsequently transported linearly to an output end of the apparatus 29. The article supply mechanisms 31 and 32 are also disposed at the input end of the apparatus 29, and on opposing sides of the selection and transport mechanism 30. A first portion of each article supply mechamsm 31 and 32 is preferably disposed spatially parallel to the selection and transport mechamsm 30, and a second portion merges, at a predetermined angle, with the selection transport mechanism 30 to supply streams of product or articles 36 to two separate positions along the selection and transport mechamsm 30. Each article supply mechamsm 31 and 32 is shown to be separated into a plurality of rectilinear article lanes 42 each with a slotted end. These merging mechamsms 30-32 are further constructed and arranged to meter individual articles 36 by raking the articles from the supply mechanisms 31 sand 32 via a fixed flight bar arrangement 41 which extends through the slotted ends of the article lanes 42, into predetermined stacked article sub-groups 37 and 38 in the cartons 35 traveling on the mechamsm 30. The stacking function of the device 29 is also accomplished by forming the first group 37 in the carton, at a low level, placing a separator or divider sheet 39 on the inserted lower group 37 via the divider sheet placement mechamsm 33 (preferably a lateral sheet feeder), and then forming a second group 38 in the carton 35, downstream at a higher level and allowing the forming upper group 38 to slide across the divider sheet 39 by the action of the flight bars 41 of the selecting mechanism 30. Merged or combined article groups 40 contained within the cartons 35 are transported downstream in the selection and transport mechanism 30 in a spaced and metered fashion between the flight bars 41. FIGS. 5 and 6 show a third embodiment of the method and assembly for forming a stacked article group in a carton. Basically, the assembly 48 inputs articles in an intermittent process and from the same side of a linear product/carton stream, in a staggered orientation. In contrast, the previous embodiments showed article infeed in a continuous process. The packaging assembly 48 basically comprises a central, longitudinally oriented carton stream or line 49, a first or low article infeed stream 50, a second or high article infeed stream 51, a divider sheet feeder 52, a low loading mechamsm 53, a high loading mechamsm 54, and a carton placer 55. These mechamsms are preferably supported on a unitary frame structure (not shown). The carton stream 49 and infeed streams 50 and 51 are preferably synchronized conveyor-type structures, which move in a downstream direction. The rotary placer type carton supply mechamsm 55 is disposed proximate the input end of the assembly 48. Cartons sleeves 56 are placed between stabilizer bars 61, or alternatively lugs, of the transport stream 49. The cartons 56 are arranged so that their ends are disposed laterally with respect to the axis of the transport mechamsm 49, with the end flaps of at least one side open. The cartons 56 are subsequently transported linearly downstream to an output end of the assembly 48. The article supply streams 50 and 51 are oriented in a spatially parallel orientation with respect to the carton transport stream 49, preferably in separate vertical planes, and on the same side of the carton conveyance line 49.. The low line 50 is disposed at the level of the carton transport line 49, while the high line 51 is disposed immediately above the low line 50. Article groups 57 and 58 shown to be pre-spaced and selected on the respective lines 50 and 51. The low and high loading mechanisms 53 and 54 are shown to be oriented laterally with respect to the carton transport line 49 and the infeed lines 50 and 51. Each loading mechanism 53 and 54 is shown to have a contact face or head attached to an elongated arm. Each loading mechamsm 53 and 54 moves laterally across its respective infeed line 50 and 51, preferably at a right angle, at predetermined intervals to contact an article group 57 or 58 and move it from the line 50 or 51 into an aligned carton 56 disposed on the carton line 49. The stacking function is accomplished by having a low article group 57 be inserted into a carton 56 conveying that carton downstream into alignment with the divider sheet feeder 52 for deposit of a divider sheet 59 onto the top of the inserted low article group 57, and then conveying that carton further downstream into alignment with the high loading mechanism 54 where the high group 58 is laterally and slidingly moved across the inserted divider sheet 59 to form the stacked article group 60. The filled cartons 56 are subsequently conveyed further downstream where ancillary processes such as carton flap gluing and closure occur. FIGS. 7 and 8 show a fourth embodiment of the method and assembly for forming a stacked article group in a carton. Basically, the assembly 67 inputs articles in an intermittent process and from opposite sides of a linear product/carton stream, in a staggered orientation. In contrast, the previous embodiment showed intermittent article infeed from the same side of the carton transport stream. The packaging assembly 67 basically comprises a central, longitudinally oriented carton transport stream or line 68, a first or low article infeed stream 69, a second or high article infeed stream 70, a divider sheet feeder 71, a low loading mechamsm 72, a high loading mechanism 73, and a carton placer 74. These mechamsms are preferably supported on a unitary frame structure (not shown). The carton stream 68 and infeed streams 69 and 70 are preferably synchronized conveyor- type structures, which move in a downstream direction. The rotary placer type carton supply mechamsm 74 is disposed proximate the input end of the assembly 68. Cartons sleeves 75 are placed between stabilizer bars 80, or alternatively lugs, of the transport stream 68. The cartons 75 are arranged so that their ends are disposed laterally with respect to the axis of the transport mechamsm 68, with the end flaps on both sides of the carton open. The cartons 75 are subsequently transported linearly downstream to an output end of the assembly 68. The article supply streams 69 and 70 are oriented in a spatially parallel orientation with respect to the carton transport stream 68, preferably in separate vertical planes. The infeed lines are further disposed on opposite sides of the carton conveyance line 68 The low line 69 is disposed at the level of the carton transport line 68, while the high line 70 is disposed immediately above the low line 69. Article groups 76 and 77 shown to be pre-spaced and selected on the respective lines 69 and 70. The low and high loading mechamsms 72 and 73 are oriented laterally with respect to the carton transport line 68 and the infeed lines 69 and 70. Each loading mechanism 72 and 73 is shown to have a contact face or head attached to an elongated arm. Each loading mechanism 72 and 73 moves laterally across its respective infeed line 69 and 70, preferably at a right angle, at predetermined intervals to contact an article group 76 or 77 and move it from the line 69 or 70 into an aligned carton 75 disposed on the carton line 68. The loading mechanisms 72 and 73 are disposed on opposite sides of the carton conveyance line 68. The stacking function is accomplished by having a low article group 76 be inserted into a carton 75 conveying that carton downstream into alignment with the divider sheet feeder 71 for deposit of a divider sheet 78 onto the top of the inserted low article group 76, and then conveying that carton further downstream into alignment with the high loading mechanism 73 where the high group 77 is laterally and slidingly moved across the inserted divider sheet 78 to form the stacked article group 79. The filled cartons 75 are subsequently conveyed further downstream where ancillary processes such as carton flap gluing and closure occur. FIGS. 9-12 show a fifth embodiment of the method and assembly for forming a stacked article group in a carton. Basically, the assembly 86 inputs articles in a continuous process without the use of raking flight bars. In contrast, previous embodiments showed either intermittent article infeed and loading processes or continuous processes which utilize raking flight bars. The packaging assembly 86 basically comprises a central, longitudinally oriented carton transport stream or line 87, a high group infeed line 89. and a high group loading mechanism 88. These mechamsms 87-89 are preferably supported on a unitary frame structure (not shown) and are synchronized conveyor-type structures, which move in a downstream direction. Additionally, a rotary placer type carton supply mechanism, a low article group article placement mechamsm, and a divider sheet placement or insertion mechanism (not shown), for example of a design discussed above, are disposed upstream in the assembly 86 to place cartons 97 in the transport stream 87 and to prelude a first article group 98 and a divider 100 into such cartons 97. At least one stream of articles supplies articles to the low article group placement mechamsm. The preloaded cartons 97 are disposed between lugs 101, or alternatively bars, of the transport stream 87. The cartons 97 are arranged so that their ends are oriented laterally with respect to the axis of the transport mechanism 86, with the end flaps on one side of the carton 97 open. The high group loading mechamsm 88 is a conveyor-type structure with top (downstream) and bottom (upstream) runs, and which comprises a plurality of loader units 91, a support assembly 90 connected to the loader units 91, and a drive mechanism (not shown) connected to the support assembly 90. The loading units 91 are oriented laterally with respect to the carton transport line 87, and move both longitudinally (downstream) in synchronization with the transport line 87. Second article groups 99 are supplied to each loader unit 91 at the upstream end of the loader mechanism 88. The second article groups 99 are aligned with and merged towards the cartons 97 traveling on the transport line 87 as the loader units 91 are conveyed downstream. At approximately the midpoint of the downstream run of the loader mechanism 88, the second article groups are loaded into the cartons 97. Each loading unit 91 comprises a loader head 92 disposed at the end of each unit 91, proximate the carton transport line 87, a support platform 93, a pusher mechamsm or face 94, a platform arm 95 and a pusher arm 96. The support platforms 93 are thin plate-like structures which have a surface area sufficient to support the article group 99, and a width equivalent to the opening width of the carton 97 side. In the downstream run, the platforms 93 travel in a plane which is level with the top surface of the divider sheets 100 inserted in the cartons 97. The platform arms 95 are attached to the back end of the platforms 93, and support and move the platforms 93. The pusher faces 94 are vertically oriented plates which are oriented over the platforms 93. An elongated pusher arm 96 is connected to the back of each pusher face 94. The pusher faces 94 slide over a range substantially equal to the length of the platform 93 in a lateral direction with respect to the carton transport stream 87. Lateral movement of the pusher faces 94 is preferably controlled by a cam system or the like associated with the support assembly 90, as is known in the art. Such movement is synchronized with a pick up phase wherein the article groups 99 are transferred from the input line 89 and a loading phase wherein the article groups 99 are transferred into cartons 97. The stacking function is accomplished by having the high group 99 laterally and slidingly moved across the inserted divider sheet 100 to form the stacked article group. This occurs as a result of the pusher face 94 being laterally moved across the platform 93 thereby pushing the article group into the carton. The filled cartons 97 are subsequently conveyed further downstream where ancillary processes such as carton flap gluing and closure occur. Referring to FIGS. 13 and 14, the method of this invention is usable to construct carriers or cartons 146 containing articles 147 which are layered on top of one another or stacked, as shown by way of example. The paperboard carrier blank or sleeve 146 is comprised of leading and trailing side panels 148 foldably connected to top panel 150 and to a bottom panel 151. End panels 152 connect the top, bottom and side panels 150, 151 and 148. Various alternative end panel configurations may be processed by the method and assembly of this invention. As shown, the carrier 146 contains a bottom layer or sub-group 153 of articles, shown for purpose of illustration as beverage cans 147, and an upper layer or sub-group 154 of cans in stacked relationship. The lower ends of the upper cans 154 are supported on a thin, paperboard divider sheet 155 (also referred to as a base or support sheet) with the bottom cans 153 resting on the bottom panel 151. The top panel 150 is disposed closely adjacent, and preferably is in contact with, the top chimes of the upper level 154 of cans to provide for a tight fit between the cans 147 and the carrier 146 Although the apparatus embodiments shown in the drawings are utilized in a beverage can cartoning operation with paperboard carrier sleeves, modifications consistent with the teachings of this invention may be made to package various other stacked containers or article in various carrier configurations. As many changes are possible to the embodiments of this invention utilizing the teachings thereof, the descriptions above, and the accompanying drawings should be interpreted in the illustrative and not the limited sense.

Claims: THAT WHICH IS CLAIMED IS: 1. A method of forming a stacked article group within a packaging unit, comprising the steps of: a) supplying a stream of packaging units; b) supplying at least two streams of articles; c) forming a first article group having at least one article in a packaging unit; d) placing a support base on a top surface of the first article group; and e) forming a second article group, having at least one article, on top of said support base of said first article group, whereby a stacked article group is formed. 2. The method of Claim 1, wherein said support base has a thin, substantially flat, rectilinear configuration with a surface area substantially coextensive with that of the top surface of said first article group. 3. The method of Claim 2, wherein said support base is constructed of paperboard. 4. The method of Claim 1, wherein said stream of packaging units is linearly and longimdinally oriented, and wherein said first article group, said support base and said second article group are inserted into said packaging unit from a lateral side thereof. 5. The method of Claim 1, wherein said second article group is slidingly moved across said support base to form said stacked article group. 6. The method of Claim 5, wherein said method is continuous. 7. The method of Claim 5, wherein said method is intermittent. 8. The method of Claim 6, wherein two article streams are supplied, and wherein each said article stream is further segregated into at least two rectilinear article lanes, and wherein said article lanes intersect said stream of packaging units at a predetermined angle and wherein said first and second article groups are formed in a packaging unit by being raked from said article lanes. 9. The method of Claim 8, wherein said article streams are disposed at vertically separate and distinct horizontal planes. 10. The method of Claim 9, wherein a first said article stream is supplied at a first longitudinal position in said stream of packaging umts, and a second said article stream being supplied at a second, distinct longitudinal position in said stream of packaging units, said first article group being formed at said first position, said second article group being formed at said second position, and said support base being placed at a position between said first and said second positions. 11. The method of Claim 10, wherein said first article stream is further supplied at a first lateral side of said stream of packaging units and said second article stream is supplied at a second lateral side thereof. 12. The method of Claim 10, wherein said first and second article streams are supplied at a first lateral side. 13. The method of Claim 7, wherein a first stream of articles are input into a first longitudinal stream of moving first article groups disposed at a first vertical level, and a second stream of articles are input into an a longitudinal stream of moving second article groups disposed at a second vertical level above said first vertical level, said moving first and second article groups being synchronized with said stream of packaging units, each said first article group being laterally moved into a packaging unit at a predetermined point and from a first lateral side of said stream of packaging units, and each said second article group being laterally moved onto said support base at a second predetermined point and from said first lateral side. 14. The method of Claim 7, wherein a first stream of articles are input into a first longitudinal stream of moving first article groups disposed at a first vertical level, and a second stream of articles are input into an a longitudinal stream of moving second article groups disposed at a second vertical level above said first vertical level, said moving first and second article groups being synchronized with said stream of packaging units, each said first article group being laterally moved into a packaging unit at a predetermined point and from a first lateral side of said stream of packaging units, and each said second article group being laterally moved onto said support base at a second predetermined point and from a second lateral side of said stream of packaging umts. 15. The method of Claim 6, wherein said second article group is formed by forming a continuous, longitudinal stream of moving second article groups disposed at a predetermined vertical level above a level of the top of said first article group, said stream being disposed adjacent a side of and spatially parallel to said stream of packaging units, synchronizing said moving second article groups with said stream of packaging umts, continuously laterally moving said synchronized second article groups onto said support base from said side of said stream of packaging units.

Inventors: OLSON ALLEN L, ZIEGLER KELLY W, OLSON, ALLEN, L., ZIEGLER, KELLY, W.
Applicants: RIVERWOOD INT CORP, RIVERWOOD INTERNATIONAL CORPORATION
Application year: 1994
Main classification: B65B35
IPC codes: B65B35, B65B61